CLARKE COUNTY POLICE DEPARTMENT GENERATOR REPLACEMENT SECTION DIESEL ENGINE - GENERATOR SET

Transcription

1 GENERATOR REPLACEMENT SECTION DIESEL ENGINE - GENERATOR SET PART 1 - GENERAL 1.01 RELATED DOCUMENTS A. The General and Supplementary Conditions and General Requirements apply to the work specified in this Section. B. The provisions and requirements of Division 26, Section "Electrical General", of this Specification shall apply to the work specified in this Section WORK INCLUDED 1.03 SCOPE A. Provide labor and material to install a standby diesel engine - generator set of the latest commercial type and design as specified herein. A. This specification covers requirements for providing a factory built, prototype tested, production tested, field tested, complete and operable standby electric generating system in an weatherproof outdoor enclosure, including all devices and equipment specified herein, shown on the drawings, and/or as required for the service. Materials and equipment shall be new and current, delivered to the site completely wired, tested, and ready for installation. This system shall include the following: 1. Engine-generator control console resiliently mounted on generating set shall include complete engine start-stop control and monitoring system. 2. Starting batteries with battery charger for enginegenerator set. 3. Mounted and loose accessories, control devices, and other equipment as specified herein and/or as shown on drawings. 4. Such other components, accessories, parts, tests, documents, and services, as needed to meet the performance requirements of this specification.

2 GENERATOR REPLACEMENT SAFETY STANDARD A. The electric generating system must meet all requirements of NFPA including design specifications, prototype tests, one-step full-load pickup, and installation acceptance. B. The responsibility for performance to this specification in its entirety cannot be split up among individual suppliers of components comprising the system, but must be assumed solely by the supplier of the system. The manufacturer shall furnish schematic and wiring diagrams for the enginegenerator set. C. All controls shall be the standard of the manufacturer, who is engaged in the manufacture of generators and has them available for sale on the open market. Control parts shall be identified by part numbers of this manufacturer and shall have second source listing where applicable. Control systems that are supplied by a sub-vendor or subcontractor of the vendor and not incorporated within the documentation drawings of the generator manufacturer are not acceptable LITERATURE A. The manufacturer shall have printed literature and brochures describing the standard series specified (not a one-of-a-kind fabrication). Unless specified otherwise herein, all performance data and other information shall be as on the manufacturer's printed literature. Performance data shall be the result of test procedures in accordance with nationally recognized standards, plus such other procedures that are judged necessary by the manufacturer to insure maximum service reliability for emergency and standby power systems, and shall be available for inspection by the Engineer upon request SUBMITTALS A. The Contractor shall furnish information showing manufacturer s model numbers, dimensions, and weights for the engine, generator, and major auxiliary equipment. B. Substitutions: The types, classes, and catalog numbers hereinafter state, and employed to establish the class and quality of apparatus and equipment required for this work. In general, all catalog numbers given are Kohler; however, apparatus and equipment effectively equal in all respects to

3 GENERATOR REPLACEMENT that described as made by Generac, Caterpillar, KatoLight or Cummin-Onan are acceptable. C. The Contractor shall submit copies of pertinent drawings and schematic diagrams for approval and shall include the following: 1. Engine generator set including plans and elevations or riser views clearly indicating entrance points or each of the interconnections required. The engine-generator set shall conform to EPA Tier I compliance. 2. Engine generator / exciter control cubicle. 3. Fuel consumption rate curves at various loads, ventilation and combustion CFM requirements. 4. Exhaust mufflers (with critical silencer type). 5. Battery charger, battery, and battery racks. 6. Fuel tank oil fill connections. 7. Above ground fuel oil tank complete with level float control and rain shield. 8. Factory fabricated outdoor sound attenuated weather housing with radiator exhaust bird screen. Maximum enclosure dimension shall be 18 6 (L)x6 10 (W)x10 4 (H). 9. Actual shop drawings of electrical diagrams including schematic diagrams, and interconnection wiring diagrams for all equipment to be provided. 10. Legends for all devices on all diagrams. 11. Sequence of operation explanations for all portions of all schematic wiring diagrams. NOTE: The specified standby KW shall be for continuous standby rating during entire interruption of the normal utility, regardless of the length of the interruption source, and shall be certified to this effect by the manufacturer for the actual unit supplied. These ratings must be substantiated by manufacturer's standard published curves. Special ratings or maximum ratings are not acceptable.

4 GENERATOR REPLACEMENT PART 2 - PRODUCTS 2.01 MANUFACTURER A. The Generator shall be manufactured by Kohler; Caterpillar, Generac, KatoLight or Cummin, sized as indicated on the plans. B. The Generator (engine and alternator) shall be mounted in an enclosure suitable for outdoor installation ENGINE A. The engine shall be liquid cooled, In-Line type, four-stroke cycle, compression ignition, diesel. It shall meet specifications when operating on Number 2 domestic burner oil. Two stroke cycle engines or those diesel engines requiring premium fuels will not be considered. The engine shall be equipped with fuel, lube oil, intake air filters, lube oil cooler, fuel priming pump, engine driven water pump, anti-freeze and unit mounted instrument panel and feeder circuit breakers. 1. Governor: A governor shall maintain frequency regulation not to exceed 5% (3 hertz) from no load to full rated load. 2. Mounting: The units shall be mounted on a structural steel sub-base. 3. Safety Devices: Safety shut-off for high water temperature, low oil pressure, overspeed, and engine overcrank, etc. shall be provided with two (2) D.P.D.T. contacts wired out to a separate terminal box for those initiating devices mounted on the machine. 4. Guards: Guards shall be provided over all exposed moving parts as required by OSHA. 5. Jacket Water Heater: Unit mounted thermal circulation type water heaters incorporating a thermostatic switch shall be furnished to maintain engine jacket water to 70 F. The heaters shall be 4000 watt, 208 volt, single phase, 60 hertz.

5 GENERATOR REPLACEMENT ALTERNATOR A. Alternator shall be rated 125 KW stand-by rated service at 0.8 power factor, 277/480 volts, three phase, four wire, 60 hertz, 1800 RPM. B. The alternator shall be a three phase, 60 hertz, single bearing, rotating field, synchronous type, wound at a 2/3 pitch, built to NEMA standards. A voltage regulator shall be provided to match the characteristics of the generator and engine. Voltage regulation shall be +2% from no load to full rated load. Readily accessible voltage drop, voltage level and voltage gain controls shall be provided. Voltage level adjustment on instrument panel shall be a minimum of +5%. Generator and exciter shall be inherently capable of parallel operation with other power sources of equivalent electrical characteristics, and stator shall include twelve leads, for easy load connection and grounding of the neutral point. C. Maximum voltage dip shall be limited to 10% with computer equipment load. D. Unit shall be cushion mounted on rubber pads specially designed for the vibration isolation of the unit. E. A minimum 100 watt, 120 volt space heater shall be provided, with a thermostat, in the generator exciter end enclosure COOLING SYSTEM A. A radiator with blower type fan shall be sized to maintain a safe operation of 125 degrees F., ambient temperature. Air flow restriction from the radiator shall not exceed 0.5" water column. B. The engine cooling system shall be pretreated by the system supplier for the inhibition of internal corrosion and freezing which will provide freeze inhibition to -20 degrees Fahrenheit EXHAUST SYSTEM A. A critical type silencers with rain cap, muffler companion flanges, and flexible stainless steel exhaust fitting properly sized shall be furnished. Exhaust pipe size shall be sufficient to ensure that exhaust back pressure does not exceed the maximum limitations specified by the engine manufacturer.

6 GENERATOR REPLACEMENT IN-BASE FUEL TANK A. Provide in-base fuel storage tank with minimum capacity to operate equipment at full load for a minimum of 72 hours. The fuel storage tank shall have low level alarm 2PDT contacts rated 10 A, 120V inductive, to signal when there is only twelve (12) hours of fuel in the fuel storage tank. A second Low-Low alarm shall sound when there is only six (6) hours of fuel in the storage tank. Fuel tank shall be filled to capacity prior to Facilities acceptance. B. In-base tank shall be double wall construction with alarm between structures for leak detection AUTOMATIC STARTING SYSTEM A. Starting Motor: A DC electric starting system with positive engagement shall be furnished. The motor voltage shall be as recommended by the engine manufacturer and suitable for cold temperature starts. B. Automatic Control: Fully automatic generator set start-stop controls in the generator control panel shall be provided. Controls shall provide shutdown for low oil pressure, high water temperature, overspeed, overcrank. Controls shall include a 30 second single cranking cycle limit with lockout. Unit shall start and carry full load in maximum 10 seconds after power failure. C. Battery Charging Alternator: A belt driven battery charging alternator rated at, 35 amp DC shall be provided with transistorized voltage regulator. D. Battery: A lead-acid maintenance-free battery of the heavyduty diesel starting type suitable for outdoor temperature of -20 F. shall be provided. Battery voltage shall be compatible with the starting system. The battery shall be rated to suit the starting requirement. Necessary cables and clamps shall be provided. E. Battery Rack: Battery rack shall be provided for battery and shall conform to NEC (a)(1). They shall be constructed of metal and so treated as to be resistant to deteriorating action by battery electrolyte. Further, construction shall be such that non conducting insulation material directly supports the cells. F. A float type battery charger, compatible with the batteries selected, shall be furnished at the engine which shall

7 GENERATOR REPLACEMENT maintain the starting batteries at full charge. The charging system shall permit charging from either the normal or the emergency power source. It shall have an equalize rate and a float rate charging system. An ammeter and voltmeter shall indicate the charge rate and the circuit shall be protected by either fuses or circuit breakers. The charger or charging circuit shall be so designed that it will not be damaged during the engine cranking cycle, for example, by a current limiting charger or a crank disconnect relay. It shall also be capable of recharging a discharged battery in 12 hours while carrying normal loads. The charger shall be equipped with alarm relays as required for remote annunciation equipment. A battery heater is required and be wired complete within the enclosure GENERATOR CONTROL PANEL A. A generator mounted NEMA 1 type vibration isolated 14 gauge steel control panel shall be provided. Panel shall contain, but not be limited to the following equipment. 1. Frequency Meter, 3-1/2", dial type. 2. Voltmeter, 3-1/2", 2% accuracy. 3. Ammeter 3-1/2", 2% accuracy. 4. Ammeter-Voltmeter phase selector switches. 5. Automatic starting controls as specified. 6. Voltage level adjustment rheostat. 7. Contacts for remote alarms wired to terminal block. 8. "Run" indicator lamp. 9. Individual fault indicator lights for low oil pressure, high water temperature, overspeed, overcrank, and low water temperature. Provide lamp test feature. 10. Running time meter, oil pressure gauge, battery charging ammeter and water temperature gauges. 11. Engine selector switch; "RUN-STOP-REMOTE" which works in conjunction with transfer switch test switch. 12. Ground lugs for grounding of system.

8 GENERATOR REPLACEMENT MAIN LINE CIRCUIT BREAKERS A. Molded case circuit breakers mounted in generator enclosure shall be installed as a load circuit interrupting and protection devices. Breakers shall operate both manually for normal switching functions and automatically during overload and short circuit conditions. Circuit breaker shall have adjustable trip settings. B. The trip unit for each pole shall have elements providing inverse time delay during overload conditions and instantaneous magnetic tripping for short circuit protection. The circuit breaker shall meet standards established for Underwriter's Laboratories, National Electric Manufacturer's Association, and National Electrical Code. C. Provide circuit breakers, (1) at 200A, 480V - 3 pole, with 35k symmetrical short circuit rating WEATHER ENCLOSURE A. Enclosure shall be sound attenuated and weather protective. B. The sound attenuation shall conform to Level II. C. Size of enclosure shall accommodate the engine-generator set and be mounted onto the in-base fuel storage tank base. D. Finish of the outdoor enclosure shall at recommendation of the Police Department and Athens-Clarke County Facilities Management AUTOMATIC LOAD TRANSFER SWITCH A. Transfer switch shall be rated at 200AMP at 277/480V, 4 pole (field verify existing rating). Contact Engineer if there is a rating conflict. Transfer switch shall be rated and marked for total system load. The contractor is required to field verify the existing transfer switch size before ordering new replacement. Inform Project Engineer and Facilities Management Division of any equipment conflict prior to ordering new equipment. B. Transfer switch serving three phase four wire loads shall be four pole with a switched neutral. Neutral contacts must be on the same shaft as the associated main contacts and have the same continuous current rating and withstand current rating. Neutral contacts shall break last and make first.

9 GENERATOR REPLACEMENT C. Transfer switch shall be the automatic type. D. Transfer switch shall be wall mounted in a NEMA 1 enclosure. Enclosures shall have hinged door with three point latching. E. Operation shall be inherently double-throw whereby all contacts move simultaneously. Electrical spacing shall be equal to or exceed those listed in Table 15.1 of UL Only those main contact structures specifically designed for transfer switch service shall be acceptable. An overload or short circuit shall not cause the switch to go to a neutral position. A manual operating handle shall be provided. All main contacts shall be silver alloy type protected by arc quenchers and, for switches rated 600 amps and larger, by arching contacts. Operating transfer time shall be 1/15 second or less on switches rated below 600 amps. F. All switch and contacts, coils, springs and control elements shall be removable from the front of the transfer switch without removal of the switch panel from the enclosure and without disconnecting power conductors or drive linkages. Control and sensing relays shall be continuous duty industrial type with minimum contact rating of ten amps. G. Transfer switch shall be rated to withstand in RMS symmetrical amperes not less than the available symmetrical RMS amperes when protected by the circuit protective device on the line side of the transfer switch. Withstand rating of switch shall be based on switch contacts not welding under fault conditions. Provide switch with current limiting fuses to increase current withstand rating when switch is not rated for fault duty. H. The control panel for each automatic transfer switch shall contain the following accessories: 1. Engine starting contacts to provide for generator starting. 2. Adjustable Undervoltage Sensors: These undervoltage sensors shall be field adjustable, close differential type with % pickup and 74-98% drop out. Relays are to be connected across live lines position test switch for engine test. a. TEST - Simulates a normal power loss to control unit for testing of an engine-generator set, including

10 GENERATOR REPLACEMENT transfer of load. The system shall provide "System Test Without Load Transfer" when required. b. NORMAL - This is the normal operating position that restores the load to the normal source after a test and after time delays. c. RETRANSFER - Momentary position, overrides the retransfer time delay to cause the immediate return of the transfer switch to the normal power source after a test or actual power outage. 4. Adjustable 0.5 to 6 second time delay on starting of SPSS to override momentary power dips and interruptions of the normal services. Time delay shall be factory set at 1 second. 5. Time delay on transfer to standby adjustable from 0 to 60 seconds, factory set at 0 seconds. 6. Push button to bypass time delay on re-transfer to normal. 7. Close differential voltage sensing shall be provided on all phases of the normal power supply. The pickup voltage shall be adjustable from 85% to 100% of nominal and the dropout voltage shall be adjustable from 75% to 98% of the pickup value. The transfer to emergency will be initiated upon reduction of normal source to 85% of nominal voltage and re-transfer to normal shall occur when normal source restores to 95% of nominal. 8. Independent single phase voltage and frequency sensing of the emergency source. The pickup voltage shall be adjustable from 85% to 100% of nominal. Pickup frequency shall be adjustable from 90% to 100% of nominal. Transfer to emergency upon normal source failure when emergency source voltage is 90% or more of nominal and frequency is 95% or more of nominal. 9. A time delay on re-transfer to normal source. The time delay shall be automatically bypassed if the standby source fails and normal source is available. The time delay shall be field adjustable from 0 to 25 minutes and factory set at 15 minutes. 10. Provide an unloaded running time delay for standby generator cool-down, factory set at 5 minutes.

11 GENERATOR REPLACEMENT Pilot light for indicating switch in normal position (include fuses and auxiliary contact). 12. Pilot light for indicating switch in standby position (include fuses and auxiliary contact). 13. An exerciser for exercising standby power plant on a weekly basis shall be provided in the transfer switch. Exerciser shall be set to exercise standby plant for one half hour per week under load. Time of plant exercise shall be set in field. Exerciser timer shall have reserve power back-up, either by battery or spring-wound clock, to ride through power outages to the switch. 14. One auxiliary contact closed on emergency and one auxiliary contact open on emergency. 15. Separate ground lugs. 16. Disconnect plug. 17. Control and annunciation circuits shall be installed in separate conduit from power cables REMOTE ANNUNCIATOR PANEL A. Provide a remote generator annunciator panel per NFPA-76A located where shown on the Drawings. It shall contain visual signal lamps which shall indicate the following conditions: 1. Generator running. 2. Over-crank. 3. Low Oil Pressure. 4. High Engine Temperature. 5. Low Engine Temperature. 6. Overspeed. 7. Battery malfunction. 8. Low Battery Voltage. 9. Over voltage. 10. Engine switch "AUTO" position.

12 GENERATOR REPLACEMENT Fuel level low. 12. Fuel level low-low. 13. Remote fuel level low. 14. Remote fuel pump stop. B. Remote Generator Annunciator panel shall also contain an audible alarm horn for specified malfunction condition and an associated switch marked "NORMAL" and "OFF". Audible alarm conditions are: 1. Over-crank. 2. Low Oil Pressure. 3. High Engine Temperature. 4. Low Engine Temperature. 5. Over speed. 6. Over voltage. 7. "Auto" Position. 8. Fuel Level. C. Coordinate with Athens-Clarke County Facilities Management on locating the remote annunciator panel in the Police Department office replacing existing unit MANUFACTURING A. The engine, including engine block, oil pan, and cylinder heads, generator and all major items of auxiliary equipment shall be manufactured in the U.S. by a single manufacturer currently engaged in the production of such equipment. The electric generating system described herein, including these components shall be factory built, factory tested, and shipped by this single manufacturer, so there is one source of supply and responsibility for warranty, parts, and service. B. The unit shall be shipped to the job site by a manufacturer's authorized dealer having a parts and service facility within a 50 mile radius of the job site. In addition, and in order not to penalize the Owner for service or repairs to the

13 GENERATOR REPLACEMENT TESTING emergency system, the bidding set supplier must have no less than eighty percent (80%) of all engine replacement parts in his stock at all times. Certified proof of this requirement shall be available from the dealer and a personal inspection of the dealer's facilities shall be made by the designing engineer or his appointed representative to substantiate claims made by the generator set supplier. A. The intent of this specification is to provide equipment of proven reliability and compatibility. Three separate series of tests shall be performed: Factory Prototype Model Tests, Factory Production Model Tests, and Field Tests. 1. Factory Prototype Model Tests: The electric generating system consisting of prime mover, generator, governor, coupling and all controls must have been tested as complete unit on representative engineering prototype model as required by NFPA The tests, being potentially damaging to the equipment tested, must not be performed on equipment to be sold, but on separate prototype models and specified by NFPA , paragraph thru and their accomplishment certified by means of documentation of the tests accompanying submittal data. 2. Factory Production Model Tests: Before shipment of the equipment, the engine-generator sets shall be tested under rated load and power factor for performance and proper functioning of control and interfacing circuits. Testing at unity power factory only (resistance banks only) is not acceptable, since KW output is affected by the higher generator efficiency at unity power factory, and the KVAR for motor starting and regulation loads varies with power factor. Tests shall include: a. Single step load pickup per NFPA , paragraph b. Transient and voltage dip responses and steady state voltage and speed (frequency) checks. 3. Field Tests After Installation: a. The complete installation shall be initially started and checked out for operational compliance by factory-trained representative of the enginegenerator set manufacturer. The engine lubrication

14 GENERATOR REPLACEMENT oil as recommended by the manufacturer for operation under specified environmental condition, shall be provided by the engine-generator set supplier. b. Upon completion of initial start-up and system checkout, the supplier of the system shall perform a field test. Testing shall be done in the presence of the Owner's engineer or his appointed representative only after the unit is permanently installed in accordance with the plans and Specifications. Testing shall be for a period of four (4) hours under facility load. c. With the emergency load at normal operating level, a power failure is initiated by opening all switches or breakers supplying the normal power to the building or facility. Records shall be maintained throughout the tests of time-of-day, coolant temperature, cranking time until prime mover starts and runs, time required to come up to operating speed, voltage and frequency overshoot, time required to achieve steadystate condition with all switches transferred to the emergency position, voltage, frequency, current, oil pressure, ambient air temperature, kilowatts, power factory, battery charger rate at 5 minute intervals for the first 15 minutes, and at 15 minute intervals for the first 15 minutes, and at 15 minute intervals thereafter. Continue this load test for 4 hours observing and recording load changes and the resultant effect on voltage and frequency. Return normal power, record the time delay on retransfer for each switch (set for 15 minutes minimum) and the time delay on prime mover cool down period and shutdown. Upon completion of the above test, allow the prime mover to cool down for 5 minutes. Then apply full rated load (nameplate KW) consisting of building load supplemented by a load bank if required. Unity power factor is suitable for on-site testing, provided that rated load tests at power factor have been performed by the manufacturer prior to shipment. This fullload pickup shall be in one step immediately upon reaching rated r/min. 4. All test results must forward to the engineer office for review and verifications. Final reports must be included as part of the close out document - Owner Manual.

15 GENERATOR REPLACEMENT START-UP AND INSTRUCTIONS A. Upon completion of the installation, start up shall be performed by the engine manufacturers' trained dealer service representative. All costs related to same shall be borne by the Electrical Contractor. Architect/Engineer shall be notified 14 days prior to the acceptance test. B. Operating and maintenance instruction manuals shall be supplied and procedures explained to operating personnel SYSTEM SERVICE CONTRACT A. The supplier of the standby power system must provide a copy of and make available to the Owner his standard service contract which, at the Owner's option, may be accepted or refused. This contract will accompany any documents, drawings, catalog cuts, specification sheets, wiring or outline drawings, etc., submitted for approval to the designing engineer. The contract shall be for the complete power system WARRANTY A. The complete standby electric power system, including 1800 r/min. engine-generator set and transfer switch equipped with set exerciser, and running time meter, shall be warranted for a period of five (5) years from the date of initial start-up. Multiple warranties for individual components (engine, generator, controls, etc.) will not be acceptable. Satisfactory warranty documents must be provided. This warranty shall be detailed in available written documents. In the judgment of the specifying authority, the manufacturer supplying the warranty for the complete system must have necessary financial strength and technical expertise with all components supplied to provide adequate warranty support VIBRATION ELIMINATORS A. Isolators shall be steel spring type, sized to suit engine generator total weight and have bolt down provisions. The location of isolators shall be coordinated with the Structural Contract Documents and Manufacturer's recommended locations.

16 GENERATOR REPLACEMENT PART 3 - EXECUTION 3.01 GROUNDING REQUIREMENTS A. The Emergency Generator grounding system shall be in accordance with N.E.C INSTALLATION A. All the equipment associated with the Engine Generator Set and controls shall be of the same Manufacturer, who shall have sole responsibility to the system. B. Contractor shall furnish and install all items required for a complete and operational system including conduit, conductors, concrete pad, grounding system, etc EXISTING GENERATOR SET DISPPOSAL A. Contractor shall make arrangement to remove existing enginegenerator set and transport to Athens-Clarke County Facilities Management site at 2555 Lexington Road, Athens, Georgia Coordinate with Facilities Management for the receiving of the removed engine-generator set. END OF SECTION